Mazda RX8 transmission manual

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00GENERAL INFORMATION

00–00–1

SECTION00–00

Toc of SCTGENERAL INFORMATION. . . . 00-00

Toc of SCT

00–00 GENERAL INFORMATIONHOW TO USE THIS MANUAL . . . . . . . . . 00–00–1

Range of Topics . . . . . . . . . . . . . . . . . . 00–00–1Service Procedure. . . . . . . . . . . . . . . . . 00–00–2Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00–00–4Advisory Messages . . . . . . . . . . . . . . . . 00–00–4

UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–5Conversion to SI Units

(Système International d'Unités) . . . . . 00–00–5Rounding Off . . . . . . . . . . . . . . . . . . . . . 00–00–5Upper and Lower Limits . . . . . . . . . . . . 00–00–5

FUNDAMENTAL PROCEDURES . . . . . . 00–00–6Preparation of Tools and Measuring

Equipment . . . . . . . . . . . . . . . . . . . . . . 00–00–6Special Service Tools . . . . . . . . . . . . . . 00–00–6Disassembly . . . . . . . . . . . . . . . . . . . . . 00–00–6

Inspection During Removal, Disassembly . . . . . . . . . . . . . . . . . . . . 00–00–6

Arrangement of Parts . . . . . . . . . . . . . . 00–00–7Cleaning of Parts . . . . . . . . . . . . . . . . . 00–00–7Reassembly . . . . . . . . . . . . . . . . . . . . . 00–00–7Adjustment . . . . . . . . . . . . . . . . . . . . . . 00–00–8Rubber Parts and Tubing . . . . . . . . . . . 00–00–8Hose Clamps . . . . . . . . . . . . . . . . . . . . 00–00–8Torque Formulas . . . . . . . . . . . . . . . . . 00–00–8Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–9

ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00–00–9Connectors . . . . . . . . . . . . . . . . . . . . . . 00–00–9

SAE STANDARDS . . . . . . . . . . . . . . . . . 00–00–11ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00–00–11

End of Toc

HOW TO USE THIS MANUALCHU000000001M01

Range of Topics• This manual contains procedures for performing all required service operations. The procedures are divided

into the following five basic operations:— Removal/Installation— Disassembly/Assembly— Replacement— Inspection— Adjustment

• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.

GENERAL INFORMATION

00–00–2

Service ProcedureInspection, adjustment

• Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations.

49 H002 671

49 H032 322

49 1232 670A

SHOWS PROCEDURE ORDERFOR SERVICE

Fluid Pressure Inspection1. Assemble the SSTs as shown in the figure.

Tightening torque

SHOWS TIGHTENINGTORQUESPECIFICATIONS

CautionConnect the gauge set from underthe vehicle to prevent contact withthe drive belt and the cooling fan.

39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}

WGIWXX0009E

GENERAL INFORMATION

00–00–3

00–00

Repair procedure1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit

together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions.

2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown.

3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. Refer to this information when servicing the related part.

YLU000WA0

GENERAL INFORMATION

00–00–4

Symbols• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols

show application points or use of these materials during service.

Advisory Messages• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this

manual.

Warning• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Caution• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

Note• A Note provides added information that will help you to complete a particular procedure.

Specification• The values indicate the allowable range when performing inspections or adjustments.

Upper and lower limits• The values indicate the upper and lower limits that must not be exceeded when performing inspections or

adjustments.End Of Sie

Symbol Meaning Kind

Apply oilNew appropriate engine oil or gear oil

Apply brake fluid New appropriate brake fluid

Apply automatic transaxle/transmission fluid

New appropriate automatic transaxle/transmission fluid

Apply grease Appropriate grease

Apply sealant Appropriate sealant

Apply petroleum jelly

Appropriate petroleum jelly

Replace part O-ring, gasket, etc.

Use SST or equivalent Appropriate tools

OILOIL

BRAKEFLUID

AATFTF

GR

EA

SE

GR

EA

SE

SEALANT

P

R

SST

GENERAL INFORMATION

00–00–5

00–00

UNITSCHU000000002M01

Conversion to SI Units (Système International d'Unités)• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted

from these values.

Rounding Off• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit

value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

Upper and Lower Limits• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is

an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:

210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}

• The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is used as a lower limit, so the converted values are rounded up to 270 and 39.

End Of Sie

Electric current A (ampere)Electric power W (watt)Electric resistance ohmElectric voltage V (volt)

Lengthmm (millimeter)in (inch)

Negative pressurekPa (kilo pascal)mmHg (millimeters of mercury)inHg (inches of mercury)

Positive pressure

kPa (kilo pascal)

kgf/cm2 (kilogram force per square centimeter)psi (pounds per square inch)

Number of revolutions rpm (revolutions per minute)

Torque

N·m (Newton meter)kgf·m (kilogram force meter)kgf·cm (kilogram force centimeter)ft·lbf (foot pound force)in·lbf (inch pound force)

Volume

L (liter)US qt (U.S. quart)Imp qt (Imperial quart)ml (milliliter)cc (cubic centimeter)cu in (cubic inch)fl oz (fluid ounce)

Weightg (gram)oz (ounce)

GENERAL INFORMATION

00–00–6

FUNDAMENTAL PROCEDURESCHU000000004M01

Preparation of Tools and Measuring Equipment• Be sure that all necessary tools and measuring

equipment are available before starting any work.

Special Service Tools• Use special service tools or equivalent when they

are required.

Disassembly• If the disassembly procedure is complex,

requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.

Inspection During Removal, Disassembly• When removed, each part should be carefully

inspected for malfunction, deformation, damage and other problems.

CHU0014W003

49 SE01 310

WGIWXX0024E

WGIWXX0027E

WGIWXX0028E

GENERAL INFORMATION

00–00–7

00–00

Arrangement of Parts• All disassembled parts should be carefully

arranged for reassembly.• Be sure to separate or otherwise identify the parts

to be replaced from those that will be reused.

Cleaning of Parts• All parts to be reused should be carefully and

thoroughly cleaned in the appropriate method.

Warning•••• Using compressed air can cause dirt and

other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air.

Reassembly• Standard values, such as torques and certain

adjustments, must be strictly observed in the reassembly of all parts.

• If removed, the following parts should be replaced with new ones:— Oil seals— Gaskets— O-rings— Lock washers— Cotter pins— Nylon nuts

• Depending on location:— Sealant and gaskets, or both, should be

applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage.

— Oil should be applied to the moving components of parts.

— Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.

WGIWXX0029E

WGIWXX0030E

WGIWXX0031E

CHU0014W006

GENERAL INFORMATION

00–00–8

Adjustment• Use suitable gauges and testers when making

adjustments.

Rubber Parts and Tubing• Prevent gasoline or oil from getting on rubber

parts or tubing.

Hose Clamps• When reinstalling, position the hose clamp in the

original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit.

Torque Formulas• When using a torque wrench-SST or equivalent

combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.

A : The length of the SST past the torque wrench drive.L : The length of the torque wrench.

CHU0014W005

WGIWXX0034E

WGIWXX0035E

Torque Unit FormulaN·m N·m × [L/(L+A)]

kgf·m kgf·m × [L/(L+A)]kgf·cm kgf·cm × [L/(L+A)]ft·lbf ft·lbf × [L/(L+A)]in·lbf in·lbf × [L/(L+A)]

01

12

2

33

SST

A L

WGIWXX0036E

GENERAL INFORMATION

00–00–9

00–00

Vise• When using a vise, put protective plates in the

jaws of the vise to prevent damage to parts.End Of Sie

ELECTRICAL SYSTEMCHU000000006M01

ConnectorsDisconnecting connectors

• When disconnecting connector, grasp the connectors, not the wires.

• Connectors can be disconnected by pressing or pulling the lock lever as shown.

Locking connector• When locking connectors, listen for a click

indicating they are securely locked.

PROTECTIVE PLATES

CHU0014W010

GOOD NO GOOD

CHU0000W014

WGIWXX0042E

WGIWXX0043E

GENERAL INFORMATION

00–00–10

Inspection• When a tester is used to inspect for continuity or

measuring voltage, insert the tester probe from the wiring harness side.

• Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side.

Caution•••• To prevent damage to the terminal, wrap

a thin wire around the tester probe before inserting into terminal.

End Of Sie

GOOD NO GOOD

CHU0000W011

GOOD NO GOOD

CHU0000W012

GENERAL INFORMATION

00–00–11

00–00

SAE STANDARDSCHU000000003M02

• In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents.

#1 : Diagnostic trouble codes depend on the diagnostic test mode.#2 : Controlled by the PCM#3 : Device that controls engine and powertrain#4 : Directly connected to exhaust manifold

End Of SieABBREVIATIONS

CHU000000011M02

End Of Sie

SAE StandardRemark

SAE StandardRemark

Abbreviation Name Abbreviation NameAP Accelerator Pedal MAP Manifold Absolute PressureAPP Accelerator Pedal Position MAF Mass Air FlowACL Air Cleaner MAF sensor Mass Air Flow SensorA/C Air Conditioning MFL Multiport Fuel InjectionA/F Air Fuel Ratio OBD On-board Diagnostic SystemBARO Barometric Pressure OL Open LoopB+ Battery Positive Voltage OC Oxidation Catalytic ConverterCMP sensor Camshaft Position Sensor O2S Oxygen SensorLOAD Calculated Load Value PNP Park/Neutral PositionCAC Charge Air Cooler PID Parameter IdentificationCLS Closed Loop System PSP Power Steering PressureCTP Closed Throttle Position PCM Powertrain Control Module #3CPP Clutch Pedal Position

PAIR Pulsed Secondary Air Injection Pulsed injectionCIS Continuous Fuel Injection

SystemCKP sensor Crankshaft Position Sensor

AIR Secondary Air InjectionInjection with air pump

DLC Data Link ConnectorDTM Diagnostic Test Mode #1DTC Diagnostic Trouble Code(s) SAPV Secondary Air Pulse ValveDI Distributor Ignition

SFI Sequential Multiport Fuel InjectionDLI Distributorless Ignition

EI Electronic Ignition #2 3GR Third GearECT Engine Coolant Temperature TWC Three Way Catalytic ConverterEM Engine Modification TB Throttle BodyEVAP Evaporative Emission TP Throttle PositionEGR Exhaust Gas Recirculation TP sensor Throttle Position SensorFC Fan Control TCC Torque Converter ClutchFF Flexible Fuel

TCM Transmission (Transaxle) Control Module4GR Fourth Gear

GEN Generator TR Transmission (Transaxle) RangeGND Ground TC Turbocharger

HO2S Heated Oxygen Sensor With heater

VSS Vehicle Speed SensorVR Voltage Regulator

IAC Idle Air Control VAF sensor Volume Air Flow SensorIAT Intake Air Temperature

WU-TWC Warm Up Three Way Catalytic Converter #4

KS Knock SensorMIL Malfunction Indicator Lamp WOP Wide Open Throttle

SST Special Service Tool

05–11–1

05TRANSMISSION/TRANSAXLESECTION

05–11

Toc of SCTMANUAL TRANSMISSION. . . . 05-11TECHNICAL DATA . . . . . . . . . . 05-50

SERVICE TOOLS. . . . . . . . . . . 05-60

Toc of SCT

05–11 MANUAL TRANSMISSIONPRECAUTION . . . . . . . . . . . . . . . . . . . . . 05–11–2EXTENSION HOUSING COMPONENT

DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05–11–3TRANSMISSION CASE AND 6TH GEAR

COMPONENT DISASSEMBLY . . . . . . . 05–11–4Snap Ring Disassembly Note . . . . . . . . 05–11–5Clutch Hub Component (6th)

Disassembly Note . . . . . . . . . . . . . . . . 05–11–5Inner Shift Lever Disassembly Note . . . 05–11–5Clutch Hub Sleeve

Disassembly Note . . . . . . . . . . . . . . . . 05–11–5CLUTCH HOUSING COMPONENT

DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05–11–6Front Cover Disassembly Note . . . . . . . 05–11–7

SHIFT FORK AND SHIFT ROD COMPONENT DISASSEMBLY . . . . . . . 05–11–7

MAIN DRIVE GEAR AND MAINSHAFT COMPONENT DISASSEMBLY . . . . . . . 05–11–8

Bearing Disassembly Note . . . . . . . . . . 05–11–91st Gear Disassembly Note . . . . . . . . . 05–11–92nd Gear Disassembly Note . . . . . . . . . 05–11–9Reverse Gear Disassembly Note . . . . . 05–11–9

COUNTERSHAFT COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05–11–10

Roller Bearing Disassembly Note . . . . . 05–11–11Counter Drive Gear

Disassembly Note . . . . . . . . . . . . . . . . 05–11–11Counter 3rd Gear

Disassembly Note . . . . . . . . . . . . . . . . 05–11–11MANUAL TRANSMISSION

INSPECTION . . . . . . . . . . . . . . . . . . . . . 05–11–12Drive Gear Inspection . . . . . . . . . . . . . . 05–11–12Reverse Idler Gear and Reverse Idler

Shaft Inspection . . . . . . . . . . . . . . . . . 05–11–13Synchronizer Ring Inspection . . . . . . . . 05–11–13Mainshaft Inspection . . . . . . . . . . . . . . . 05–11–13Countershaft Inspection . . . . . . . . . . . . 05–11–13Clutch Hub Sleeve and Shift Fork

Inspection . . . . . . . . . . . . . . . . . . . . . . 05–11–14COUNTERSHAFT COMPONENT

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05–11–14Clutch Hub Component (3rd/4th)

Assembly Note . . . . . . . . . . . . . . . . . . 05–11–15Thrust Washer Assembly Note . . . . . . . 05–11–16Counter Drive Gear Assembly Note . . . 05–11–16

Snap Ring (Friction Gear) Assembly Note . . . . . . . . . . . . . . . . . . 05–11–17

Roller Bearing Assembly Note . . . . . . . 05–11–17Snap Ring (Roller Bearing)

Assembly Note . . . . . . . . . . . . . . . . . . 05–11–17MAIN DRIVE GEAR AND MAINSHAFT

COMPONENT ASSEMBLY. . . . . . . . . . 05–11–18Bearing Assembly Note . . . . . . . . . . . . 05–11–19Snap Ring (Bearing) Assembly Note . . 05–11–19Clutch Hub Component (5th/Reverse)

Assembly Note . . . . . . . . . . . . . . . . . . 05–11–19Snap Ring (Reverse Gear)

Assembly Note . . . . . . . . . . . . . . . . . . 05–11–20Clutch Hub Component (1st/2nd)

Assembly Note . . . . . . . . . . . . . . . . . . 05–11–206th Gear Assembly Note . . . . . . . . . . . 05–11–21Snap Ring (6th Gear) Assembly Note . 05–11–21

CLUTCH HOUSING COMPONENT, SHIFT FORK AND SHIFT ROD COMPONENT ASSEMBLY. . . . . . . . . . 05–11–22

Reverse Idler Gear Component Assembly Note . . . . . . . . . . . . . . . . . . 05–11–23

Clutch Housing Assembly Note . . . . . . 05–11–23Bolt and Gasket Assembly Note. . . . . . 05–11–233rd/4th Shift Fork and Shift Arm

(Reverse) Assembly Note . . . . . . . . . 05–11–245th/Reverse Counter Lever

Assembly Note . . . . . . . . . . . . . . . . . . 05–11–24TRANSMISSION CASE AND 6TH GEAR

COMPONENT ASSEMBLY. . . . . . . . . . 05–11–25Shift Rod Assembly Note . . . . . . . . . . . 05–11–26Transmission Case Assembly Note . . . 05–11–26Bolt and Gasket Assembly Note. . . . . . 05–11–27Oil Seal Assembly Note . . . . . . . . . . . . 05–11–27Inner Shift Lever Assembly Note . . . . . 05–11–28Clutch Hub Component (6th)

Assembly Note . . . . . . . . . . . . . . . . . . 05–11–28Snap Ring Assembly Note . . . . . . . . . . 05–11–286th Shift Fork Assembly Note. . . . . . . . 05–11–29Plug Assembly Note . . . . . . . . . . . . . . . 05–11–29

EXTENSION HOUSING COMPONENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05–11–30

Oil Seal Assembly Note . . . . . . . . . . . . 05–11–31Torsion Spring Assembly Note. . . . . . . 05–11–31

End of Toc

MANUAL TRANSMISSION

05–11–2

PRECAUTIONCHU051117010M01

1. Clean the transmission exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.

Warning•••• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.

Wear protective eye wear whenever using compressed air.

Caution•••• Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the

bearing.

2. Clean the removed parts using cleaning solvent, and dry them using compressed air.3. Clean out all holes and passages using compressed air, and check that there are no obstructions.4. Use a plastic hammer when disassembling the transmission case and other light alloy metal parts.5. Make sure each part is cleaned before assembling.6. Coat all movable parts with the specified oil.7. Replace parts whenever required.8. Remove old sealant from contact surfaces before applying new sealant.9. Assemble the parts within 10 min after applying sealant. Allow all sealant to cure at least 30 min after

assembling before filling the transmission with transmission oil.

Warning•••• Although the stand has a self-locking brake system, there is a possibility that the brake may not

hold when the transmission is held in a lopsided position on the stand. This would cause the transmission to turn suddenly, causing serious injury. Never keep the transmission tilted to one side. Always hold the rotating handle firmly when turning the transmission.

End Of Sie

MANUAL TRANSMISSION

05–11–3

05–11

EXTENSION HOUSING COMPONENT DISASSEMBLYCHU051117010M02

1. Disassemble in the order indicated in the table..

End Of Sie

14

1817

20

24

26

2510

11

12

1513

22

23 16

27

21

19

1

5

6

9

7

A

A

4

8

23

BHJ0511M101

1 Clutch release collar2 Clutch release fork3 Dust cover4 Pivot pin5 Filler plug, gasket6 Drain plug, gasket7 Neutral switch8 Back-up light switch9 Plug

10 Pressure spring11 Push pin component12 Control case13 Gasket14 Tubular pin

15 Control rod end16 Extension housing component17 Retaining ring18 Torsion spring19 Shift lever20 Shift rod21 Oil passage22 Stopper block23 Oil funnel24 Lever support25 Breather26 Baffle plate27 Oil seal

MANUAL TRANSMISSION

05–11–4

TRANSMISSION CASE AND 6TH GEAR COMPONENT DISASSEMBLYCHU051117010M03

Note• Measure the thrust and radial clearance of 6th gear before disassembly. (See 05–11–12 Drive Gear

Inspection.)


17

24

21

22

12

10 11

14

18

19

25 1

4

2

3

5

67

8

9

13

15

1620

2623

27

32

30

28

2931

SST

BHJ0511M103

1 Spring pin2 Snap ring

(See 05–11–5 Snap Ring Disassembly Note.)3 Clutch hub component (6th)

(See 05–11–5 Clutch Hub Component (6th) Disassembly Note.)

4 6th shift fork5 Synchronizer ring6 6th gear7 Needle bearing8 Thrust washer9 Pin

10 Spring pin11 Inner shift lever

(See 05–11–5 Inner Shift Lever Disassembly Note.)12 Interlock sleeve

13 Bearing cover component14 Snap ring (rear)15 Plug16 Steel ball, pressure spring17 Plug18 Shift rod19 Steel ball20 Steel ball21 Plug22 Bolt, gasket23 Bolt, gasket24 Bolt25 Transmission case26 Pressure spring, steel ball27 Retaining ring

MANUAL TRANSMISSION

05–11–5

05–11

Snap Ring Disassembly Note1. Remove the snap ring using two flathead

screwdrivers and a hammer.

Clutch Hub Component (6th) Disassembly Note1. Remove the clutch hub component (6th) and the

6th shift fork together using the SST.

Inner Shift Lever Disassembly Note1. Attach a flathead screwdriver as shown in the

figure, and remove the inner shift lever by tapping the shift rod with a plastic hammer.

Clutch Hub Sleeve Disassembly Note1. Remove the clutch hub sleeve covering the clutch

hub component with a rag to prevent the steel balls and synchronizer key springs from springing out.

End Of Sie

28 Clutch hub sleeve(See 05–11–5 Clutch Hub Sleeve Disassembly Note.)

29 Steel ball

30 Synchronizer key31 Synchronizer key spring32 Clutch hub

FLATHEAD SCREWDRIVER

CHU0511M104

49 N017 2A1

BHJ0511M105

BHJ0511M106

BHJ0511M107

MANUAL TRANSMISSION

05–11–6

CLUTCH HOUSING COMPONENT DISASSEMBLYCHU051117010M04


9

8

8

7

5

43

10

1311 12

6

1

2

A

A

1516 14

BHJ0511M108

1 Crank lever shaft2 5th/reverse counter lever3 Front cover

(See 05–11–7 Front Cover Disassembly Note.)4 Oil seal 5 Snap ring (front)6 Main drive gear, mainshaft component7 Countershaft component8 Shift fork and shift rod component

9 Reverse idler shaft10 Reverse idler gear component11 Snap ring12 Spacer13 Friction gear14 Torsion spring15 Reverse idler gear16 Clutch housing

MANUAL TRANSMISSION

05–11–7

05–11

Front Cover Disassembly Note1. Remove the front cover by prying with a flathead

screwdriver as shown in the figure.End Of Sie

SHIFT FORK AND SHIFT ROD COMPONENT DISASSEMBLYCHU051117030M01


BHJ0511M109

9 8

7

5

4

3

10

13

11

12

6

12

BHJ0511M110

1 Spring pin2 Shift arm (reverse)3 3rd/4th shift fork4 Spring pin5 Stopper block6 shift arm (5th)7 Pressure spring, steel ball

8 Shift rod9 5th/reverse shift fork10 Interlock sleeve11 1st/2nd shift fork12 Snap ring13 Shift rod

MANUAL TRANSMISSION

05–11–8

End Of SieMAIN DRIVE GEAR AND MAINSHAFT COMPONENT DISASSEMBLYCHU051117050M01

Note• Measure the thrust and radial clearance of 1st, 2nd and reverse gear before disassembly. (See 05–11–12

Drive Gear Inspection.)


9

8

75

4

3

10

13

1112

6

1

2

1918

17

15

16

14

20

29 28

27

25

2624

23

21

22

30

32

31

29

30

32

31

SST

SST

SST

SST

BHJ0511M111

1 Main drive gear component2 Synchronizer ring3 Needle bearing4 Snap ring (bearing)

(See 05–11–5 Snap Ring Disassembly Note.)5 Bearing

(See 05–11–9 Bearing Disassembly Note.)6 Main drive gear7 Snap ring (6th gear)

(See 05–11–5 Snap Ring Disassembly Note.)8 1st gear

(See 05–11–9 1st Gear Disassembly Note.)9 6th gear

10 Bearing11 Inner race12 Needle bearing

13 Synchronizer ring14 Middle ring15 Inner ring16 Steel ball17 2nd gear

(See 05–11–9 2nd Gear Disassembly Note.)18 Clutch hub component (1st/2nd)19 Synchronizer ring20 Middle ring21 Inner ring22 Needle bearing23 Snap ring (reverse gear)24 Reverse gear

(See 05–11–9 Reverse Gear Disassembly Note.)25 Clutch hub component (5th/reverse)26 Synchronizer ring

MANUAL TRANSMISSION

05–11–9

05–11Bearing Disassembly Note1. Remove the bearing using the SST.

1st Gear Disassembly Note1. Shift the clutch hub component (1st/2nd) to the 2nd gear.2. Remove the 6th gear, bearing and 1st gear

together using the SST and a press.

2nd Gear Disassembly Note1. Remove the clutch hub component (1st/2nd) and

2nd gear together using the SST and a press.

Reverse Gear Disassembly Note1. Remove the clutch hub component (5th/reverse)

and reverse gear together using the SST and a press.

End Of Sie

27 Needle bearing28 Mainshaft29 Clutch hub sleeve

(See 05–11–5 Clutch Hub Sleeve Disassembly Note.)

30 Steel ball, synchronizer key spring31 Synchronizer key32 Clutch hub

49 G030 370

BHJ0511M112

49 N017 101

BHJ0511M113

49 N017 101

BHJ0511M114

49 N017 101

BHJ0511M115

MANUAL TRANSMISSION

05–11–10

COUNTERSHAFT COMPONENT DISASSEMBLYCHU051117050M02

Note• Measure the thrust and radial clearance of 3rd and 4th gear before disassembly. (See 05–11–12 Drive

Gear Inspection.)


8

5

4

3

19

18

1716

12

2021

226

1

2SST

SST

7

SST

9

10

11

16

1514

13

BHJ0511M116

1 Snap ring (roller bearing)2 Roller bearing

(See 05–11–11 Roller Bearing Disassembly Note.)3 Snap ring (friction gear)4 Counter drive gear

(See 05–11–11 Counter Drive Gear Disassembly Note.)

5 Snap ring6 Retaining ring7 Thrust washer8 Inner race9 Counter 4th gear

10 Synchronizer ring11 Counter 3rd gear

(See 05–11–11 Counter 3rd Gear Disassembly Note.)

12 Clutch hub component (3rd/4th)13 Synchronizer ring14 Middle ring15 Inner ring16 Needle bearing17 Countershaft gear18 Clutch hub sleeve

(See 05–11–5 Clutch Hub Sleeve Disassembly Note.)

19 Steel ball20 Synchronizer key spring21 Synchronizer key22 Clutch hub

MANUAL TRANSMISSION

05–11–11

05–11

Roller Bearing Disassembly Note1. Remove the roller bearing using the SSTs and a

press.

Counter Drive Gear Disassembly Note1. Remove the counter drive gear using the SST

and a press.

Counter 3rd Gear Disassembly Note1. Remove the counter 3rd gear and clutch hub

component (3rd/4th) together using the SST and a press.

End Of Sie

49 H027 00249 B032 317

BHJ0511M117

49 N017 102

BHJ0511M118

49 G030 370

BHJ0511M119

MANUAL TRANSMISSION

05–11–12

MANUAL TRANSMISSION INSPECTIONCHU051117050M03

Drive Gear InspectionThrust clearance inspection1. Measure the thrust clearance of each gear using

a feeler gauge and a dial gauge as shown in the figure.

Thrust clearance(mm {in})

• If not within the specification, replace the malfunctioning parts.

Radial clearance inspection1. Measure the radial clearance of each gear using

a dial gauge.Radial clearance

(mm {in})

• If not within the specification, replace the synchronizer ring.

Gear Thrust clearance1st 0.15—0.40 {0.006—0.015}2nd 0.10—0.45 {0.004—0.017}3rd 0.10—0.35 {0.004—0.013}4th 0.10—0.35 {0.004—0.013}6th 0.10—0.40 {0.004—0.015}

Reverse 0.10—0.45 {0.004—0.017}

REVERSE 2ND1ST

4TH 3RD 6TH

CHU0511M120

3RD, REVERSE

CHU0511M121

1ST, 2ND, 4TH 6TH

CHU0511M122

Gear Radial clearance1st 0.015—0.066 {0.0006—0.0025}2nd 0.015—0.066 {0.0006—0.0025}3rd 0.015—0.068 {0.0006—0.0026}4th 0.065—0.115 {0.0026—0.0045}

5th (Drive gear) 0.029—0.072 {0.0012—0.0028}6th 0.015—0.068 {0.0006—0.0026}

Reverse 0.015—0.066 {0.0006—0.0025}BHJ0511M123

MANUAL TRANSMISSION

05–11–13

05–11

Reverse Idler Gear and Reverse Idler Shaft InspectionRadial clearance inspection1. Secure the reverse idler gear and reverse idler

shaft in a vise, and measure the radial clearance using a dial gauge.

Radial clearance0.040—0.082 mm {0.0016—0.0032 in}

• If not within the specification, replace the reverse idler gear and the reverse idler shaft.

Synchronizer Ring Inspection1. Set the synchronizer ring evenly in the gear, and

measure the clearance between the synchronizer ring and flank surface of the gear all around the circumference using a feeler gauge.

Clearance(mm {in})

• If not within the specification, replace the synchronizer ring.

Mainshaft Inspection1. Hold the mainshaft with the V-blocks and

measure the runout using a dial gauge as shown in the figure.

Maximum runout0.03 mm {0.0012 in}

• If it exceeds the maximum specification, replace the mainshaft.

Countershaft Inspection1. Hold the countershaft with the V-blocks and

measure the runout using a dial gauge as shown in the figure.

Maximum runout0.03 mm {0.0012 in}

• If it exceeds the maximum specification, replace the countershaft.

BHJ0511M124

Gear Clearance

1st 2nd 3rd

Inner ring 0.98—1.62 {0.04—0.06}Middle ring 0.68—1.92 {0.03—0.07}Synchronizer ring 0.88—1.72 {0.04—0.06}

4th 5th 0.80—1.60 {0.04—0.06}6th Reverse 0.88—1.52 {0.04—0.05}

BHJ0511M125

V-blocks

CHU0511M126

V-blocks

CHU0511M127

MANUAL TRANSMISSION

05–11–14

Clutch Hub Sleeve and Shift Fork Inspection1. Measure the shift fork thickness and the groove

width of the clutch hub sleeve with a vernier caliper, and calculate the clearance.

Clearance0.15—0.35 mm {0.006—0.013 in}

• If not within the specification, replace the clutch hub sleeve and shift fork.

End Of Sie

COUNTERSHAFT COMPONENT ASSEMBLYCHU051117050M04

1. Assemble in the order indicated in the table.2. Verify the following after assembly.

(1) The gear rotates smoothly when rotated by hand.(2) The synchronizer ring is not stuck..

BHJ0511M128

8

7

5

4

3

19

1817

15

16

14

13

12

20

21

22

6

1

2

R

SST

SST

RSELECTIVEUSE

7

R

SST

910

11

OIL APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

SELECTIVEUSE

SELECTIVEUSE

FRONT

FRONT

CHU0511M129

1 Clutch hub2 Synchronizer key3 Synchronizer key spring4 Steel ball5 Clutch hub sleeve6 Countershaft gear

7 Needle bearing8 Counter 3rd gear9 Inner ring

10 Middle ring11 Synchronizer ring

MANUAL TRANSMISSION

05–11–15

05–11

Clutch Hub Component (3rd/4th) Assembly Note1. Securely align the tabs on each ring of the 3rd

gear side with the installation hole of the 3rd gear and the key groove of the clutch hub.

2. Securely align the tab on the synchronizer ring of 4th gear side with the key groove of the clutch hub.

Caution•••• Do not damage the synchronizer ring

when installing the clutch hub component.

12 Clutch hub component (3rd/4th)(See 05–11–15 Clutch Hub Component (3rd/4th) Assembly Note.)

13 Synchronizer ring14 Counter 4th gear15 Inner race16 Thrust washer

(See 05–11–16 Thrust Washer Assembly Note.)17 Retaining ring18 Snap ring

19 Counter drive gear(See 05–11–16 Counter Drive Gear Assembly Note.)

20 Snap ring (friction gear)(See 05–11–17 Snap Ring (Friction Gear) Assembly Note.)

21 Roller bearing(See 05–11–17 Roller Bearing Assembly Note.)

22 Snap ring (roller bearing)(See 05–11–17 Snap Ring (Roller Bearing) Assembly Note.)

CLUTCH HUBCOMPONENT

A

B

C

A

B

CSYNCHRONIZERRING

MIDDLE RING

INNER RING

GEAR

CHU0511M143

BHJ0511M130

MANUAL TRANSMISSION

05–11–16

3. Carefully install the clutch hub component (3rd/4th) using the SSTs and a press.

Thrust Washer Assembly Note1. Install the thrust washer removed during

disassembly, and measure the clearance between the thrust washer and the installation groove using a feeler gauge.

2. Select the new thrust washer from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear with the identification mark facing up.

Clearance0—0.1 mm {0—0.0039 in}

Thrust washer size(mm {in})

Counter Drive Gear Assembly Note1. Install the counter drive gear using the SSTs.

49 F401 331

49 M005 796

BHJ0511M131

Identification mark

Thickness Identification mark

Thickness

A 3.75 {0.148} E 3.95 {0.156}B 3.80 {0.150} F 4.00 {0.157}C 3.85 {0.152} G 4.05 {0.159}D 3.90 {0.154} H 4.10 {0.161}

THRUST WASHER

CHU0511M132

49 M005 796

49 N017 104 STEEL PLATE

CHU0511M133

MANUAL TRANSMISSION

05–11–17

05–11

Snap Ring (Friction Gear) Assembly Note1. Install the snap ring removed during disassembly,

and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear.


Snap ring size(mm {in})

Roller Bearing Assembly Note1. Install the roller bearing using the SSTs.

Snap Ring (Roller Bearing) Assembly Note1. Install the snap ring removed during disassembly,





End Of Sie

Identification mark


Thickness

A 1.80 {0.071} D 1.95 {0.077}B 1.85 {0.073} E 2.00 {0.079}C 1.90 {0.075} F 2.05 {0.081}

SNAP RING

CHU0511M134

49 H025 004

49 M005 796

STEEL PLATE

CHU0511M135

Identification mark


Thickness

A 3.75 {0.148} E 3.95 {0.156}B 3.80 {0.150} F 4.00 {0.157}C 3.85 {0.152} G 4.05 {0.159}D 3.90 {0.154} H 4.10 {0.161}

SNAP RING

CHU0511M136

MANUAL TRANSMISSION

05–11–18

MAIN DRIVE GEAR AND MAINSHAFT COMPONENT ASSEMBLYCHU051117050M05


(1) The gear rotates smoothly when rotated by hand.(2) The synchronizer ring is not stuck..

98

7

54

3

10

19

1817

1516

14

13

11

12

20

2928

27

2526

24

23

21

22

30

6

1

2

33

31

32

10

79

8

SST

R

SST

SST

SST

RR

6

OIL APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

SELECTIVEUSE

SELECTIVEUSE

SELECTIVEUSE

FRONT

FRONT

FRONT

FRONT

CHU0511M137

1 Main drive gear2 Bearing

(See 05–11–19 Bearing Assembly Note.)3 Snap ring (bearing)

(See 05–11–19 Snap Ring (Bearing) Assembly Note.)

4 Synchronizer ring5 Needle bearing6 Clutch hub7 Synchronizer key8 Synchronizer key spring9 Steel ball

10 Clutch hub sleeve11 Mainshaft12 Needle bearing13 Reverse gear14 Synchronizer ring15 Clutch hub component (5th/reverse)

(See 05–11–19 Clutch Hub Component (5th/Reverse) Assembly Note.)

16 Snap ring (reverse gear)(See 05–11–20 Snap Ring (Reverse Gear) Assembly Note.)

17 Needle bearing18 2rd gear19 Inner ring20 Middle ring21 Synchronizer ring22 Clutch hub component (1st/2nd)

(See 05–11–20 Clutch Hub Component (1st/2nd) Assembly Note.)

23 Steel ball24 Synchronizer ring25 Middle ring26 Inner ring27 1st gear28 Needle bearing29 Inner race30 Bearing

MANUAL TRANSMISSION

05–11–19

05–11Bearing Assembly Note1. Install the bearing using the SSTs.

Snap Ring (Bearing) Assembly Note1. Install the snap ring removed during disassembly,


2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the main drive gear.


Snap Ring size(mm {in})

Clutch Hub Component (5th/Reverse) Assembly Note1. Securely align the tab on the synchronizer ring

with the key groove of the clutch hub.



31 6th gear(See 05–11–21 6th Gear Assembly Note.)

32 Snap ring (6th gear) (See 05–11–21 Snap Ring (6th Gear) Assembly Note.)

33 Main drive gear component

49 0500 330

49 B019 007

BHJ0511M138

Identification mark


Thickness

0 1.95 {0.077} 3 2.10 {0.083}1 2.00 {0.079} 4 2.15 {0.085}2 2.05 {0.081} 5 2.20 {0.087}

SNAP RING

CHU0511M139

BHJ0511M140

MANUAL TRANSMISSION

05–11–20

2. Carefully install the clutch hub component (5th/reverse) using the SSTs and a press.

Snap Ring (Reverse Gear) Assembly Note1. Install the snap ring removed during disassembly,


2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the mainshaft.



Clutch Hub Component (1st/2nd) Assembly Note1. Securely align the tab on each ring with the

installation hole of the 2nd gear and the key groove of the clutch hub.

Caution•••• Do not damage each synchronizer ring


49 N017 102

49 N017 104

STEEL PLATE

CHU0511M141

Identification mark


Thickness

A 1.80 {0.071} D 1.95 {0.077}B 1.85 {0.073} E 2.00 {0.079}C 1.90 {0.075} F 2.05 {0.081}

SNAP RING

CHU0511M142

CLUTCH HUBCOMPONENT

A

B

C

A

B

CSYNCHRONIZERRING

MIDDLE RING

INNER RING

GEAR

CHU0511M143

MANUAL TRANSMISSION

05–11–21

05–11

2. Carefully install the clutch hub component (1st/2nd) using the SSTs and a press.

6th Gear Assembly Note1. Install the bearing and 6th gear using the SSTs

and a press.

Snap Ring (6th Gear) Assembly Note1. Install the snap ring removed during disassembly,


2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the mainshaft.



End Of Sie

STEEL PLATE49 N017 103

49 N017 104

49 N017 102

CHU0511M144

STEEL PLATE49 N017 103

49 N017 102

CHU0511M145

Identification mark


Thickness

A 2.67 {0.105} G 3.03 {0.119}B 2.73 {0.107} H 3.09 {0.122}C 2.79 {0.110} J 3.15 {0.124}D 2.85 {0.122} K 3.21 {0.126}E 2.91 {0.115} L 3.27 {0.129}F 2.97 {0.117} – –

SNAP RING

CHU0511M146

MANUAL TRANSMISSION

05–11–22

CLUTCH HOUSING COMPONENT, SHIFT FORK AND SHIFT ROD COMPONENT ASSEMBLYCHU051117030M02

1. Assemble in the order indicated in the table..

98

7

5

4

3

10

19

18

17

1516

14

13

11

12

20

27

25

26

24

23

21

22

6

1

2

A

A

R

SST

R

R

32—47

R

SEALANT

{3.3—4.7, 24—34}

N·m {kgf·m, ft·lbf}

CHU0511M147

1 Shift rod2 Snap ring3 1st/2nd shift fork4 Interlock sleeve5 5th/reverse shift fork6 Reverse idler gear7 Torsion spring8 Friction gear9 Spacer

10 Snap ring11 Reverse idler shaft12 Countershaft component13 Reverse idler gear component

(See 05–11–23 Reverse Idler Gear Component Assembly Note.)

14 Clutch housing(See 05–11–23 Clutch Housing Assembly Note.)

15 Main drive gear and mainshaft component

16 Shift fork and shift rod component (mainshaft)17 Bolt and gasket

(See 05–11–23 Bolt and Gasket Assembly Note.)18 Shift arm (5th)19 Pressure spring, steel ball20 Shift rod 21 Stopper block22 Spring pin23 3rd/4th shift fork

(See 05–11–24 3rd/4th Shift Fork and Shift Arm (Reverse) Assembly Note.)

24 Shift arm (reverse)(See 05–11–24 3rd/4th Shift Fork and Shift Arm (Reverse) Assembly Note.)

25 Spring pin26 5th/reverse counter lever

(See 05–11–24 5th/Reverse Counter Lever Assembly Note.)

27 Crank lever shaft

MANUAL TRANSMISSION

05–11–23

05–11

Reverse Idler Gear Component Assembly Note1. Turn the friction gear counterclockwise by hand, and align the reverse idler gear hole with the friction gear.2. Insert the SST (49 N017 204) through the holes

from the reverse idler gear side, and secure the friction gear.

Clutch Housing Assembly Note1. Install the countershaft component and the

reverse idler gear component installed with the SSTs and the main drive gear and mainshaft component, shift fork and shift rod component (mainshaft) onto the clutch housing together.

2. Remove the SSTs installed to the countershaft component and the reverse idler gear component after installing.

Bolt and Gasket Assembly Note1. Install a new gasket and bolt into the clutch housing and tighten temporarily.2. Fully tighten the new gasket and bolt after installing the transmission case.

FRICTION GEAR REVERSEIDLER GEAR

49 N017 204

CHU0511M148

MAIN DRIVE GEAR AND MAINSHAFT COMPONENT

SHIFT FORK AND SHIFT ROD COMPONENT(MAINSHAFT)

COUNTERSHAFTCOMPONENT

CLUTCH HOUSING

REVERSE IDLERGEAR COMPONENT

49 N017 204

CHU0511M149

MANUAL TRANSMISSION

05–11–24

3rd/4th Shift Fork and Shift Arm (Reverse) Assembly Note1. Temporarily install the 3rd/4th shift fork and shift arm (reverse) into the clutch housing.2. Pass the shift rod through the 3rd/4th shift fork

and shift arm (reverse).3. Tap a new spring pin into the shift arm (reverse)

head.

5th/Reverse Counter Lever Assembly Note1. Install the 5th/reverse counter lever as shown in

the figure, and secure it with the crank lever shaft.End Of Sie

SHIFT ROD

3RD/4TH SHIFTFORK

SHIFT ARM(REVERSE)

CHU0511M150

5TH/REVERSE COUNTER LEVER

CRANK LEVER SHAFT

CHU0511M151

MANUAL TRANSMISSION

05–11–25

05–11

TRANSMISSION CASE AND 6TH GEAR COMPONENT ASSEMBLYCHU051117010M05


(1) The gear rotates smoothly when rotated by hand.(2) The synchronizer is not stuck..

16

10

1

42

3

56

7

8

9

14

15

2830

31

13

12

17

18

19

20

11

SST

SST

SST

24

25

2322

21

27

26

3229

11.8—21.527—48

33

13.8—23.5

23—40

12.8—23.5

13.8—23.5

24—33

24—35


SEALANTSEALANT

SEALANTSEALANT

SEALANTSEALANT

SST

R

R R

RR

R

RSEALANTSEALANT

SEALANTSEALANT

SEALANTSEALANT

{1.2—2.1, 8.7—15.8} {2.8—4.8,

20—35}{2.4—4.0, 17—29}

{1.4—2.3, 10.2—17.3}

{1.4—2.3, 10.2—17.3}

{2.5—3.3, 18—24}

{2.5—3.5, 18—25}

{1.3—2.3, 9.5—17.3} SELECTIVEUSE FRONT

FRONT

CHU0511M152

1 Clutch hub2 Synchronizer key3 Synchronizer key spring4 Steel ball5 Retaining ring6 Clutch hub sleeve7 Steel ball8 Shift rod

(See 05–11–26 Shift Rod Assembly Note.)9 Transmission case

(See 05–11–26 Transmission Case Assembly Note.)

10 Pressure spring, steel ball11 Snap ring (rear)12 Snap ring (front)13 Bolt and gasket

(See 05–11–27 Bolt and Gasket Assembly Note.)14 Bolt15 Plug16 Oil seal

(See 05–11–27 Oil Seal Assembly Note.)17 Front cover

18 Interlock sleeve19 Inner shift lever

(See 05–11–28 Inner Shift Lever Assembly Note.)20 Bearing cover component21 Pin22 Thrust washer23 Needle bearing24 6th gear25 Synchronizer ring26 Clutch hub component (6th)

(See 05–11–28 Clutch Hub Component (6th) Assembly Note.)

27 Snap ring(See 05–11–28 Snap Ring Assembly Note.)

28 Steel ball29 6th shift fork

(See 05–11–29 6th Shift Fork Assembly Note.)30 Steel ball, pressure spring31 Plug32 Spring pin33 Plug

(See 05–11–29 Plug Assembly Note.)

MANUAL TRANSMISSION

05–11–26

Shift Rod Assembly Note1. Install the SST into the clutch housing.2. Install the steel ball into the shift arm (5th).3. Taking care so that the steel ball does not drop out, carefully insert the shift rod until it contacts the SST

installed to the clutch housing.4. Turn the notch of the shift rod end toward the shift

rod A.

Transmission Case Assembly Note1. Set the shift operation system to the neutral

position.

Note• If the countershaft center bearing interferes

with the transmission case when installing, pry the roller of the bearing lightly using a screw driver covered with a rag.

NOTCH

SHIFT ROD

SHIFT ROD A

49 N017 207

CHU0511M153

NEUTRAL POSITION

VIEW FROM A

VIEW FROM A

CHU0511M154

MANUAL TRANSMISSION

05–11–27

05–11

2. Install the pressure spring and steel ball into the transmission case, then install the transmission case onto the clutch housing pressing with a pin punch so that the steel ball does not spring out.

Bolt and Gasket Assembly Note1. Tighten the transmission case mounting bolt, then tighten the new gasket and bolt A (for the reverse idler

shaft).2. Tighten bolt B tightened temporarily on the clutch

housing.

Tightening torque (Bolt A and B)24—33 N·m {2.5—3.3 kgf·m, 18—24 ft·lbf}

Oil Seal Assembly Note1. Install the new oil seal in the front cover using the

SSTs and a hammer.

STEEL BALL

SHIFT ROD

PIN PUNCH

PRESSURE SPRING

CHU0511M158

BA

BHJ0511M155

49 N017 209

49 G030 797

BHJ0511M156

MANUAL TRANSMISSION

05–11–28

Inner Shift Lever Assembly Note1. Install the inner shift lever using a suitable pipe

and a hammer.

Clutch Hub Component (6th) Assembly Note1. Securely align the tab on the synchronizer ring

with the key groove of the clutch hub.



2. Carefully install the clutch hub component (6th) using the SST.

Snap Ring Assembly Note1. Install the snap ring removed during disassembly,





BHJ0511M157

BHJ0511M130

49 N017 2A0

BHJ0511M159

Identification mark


Thickness

A 2.80 {0.110} D 2.95 {0.116}B 2.85 {0.112} E 3.00 {0.118}C 2.90 {0.114} F 3.05 {0.120}

SNAP RING

CHU0511M160

MANUAL TRANSMISSION

05–11–29

05–11

6th Shift Fork Assembly Note1. Install the 6th shift fork in the clutch hub component.2. Insert the steel ball from the transmission case.3. Pass the SST through the 6th shift fork and install in the shift rod.4. Pull the SST up, then install the steel ball,

pressure spring and plug from outside of the transmission case and secure the shift rod.

Plug Assembly Note1. Remove the SST installed to the clutch housing,

and install the plug.End Of Sie

49 N017 208

6TH SHIFT FORK

CHU0511M161

49 N017 207

BHJ0511M162

MANUAL TRANSMISSION

05–11–30

EXTENSION HOUSING COMPONENT ASSEMBLYCHU051117010M06

Note• Do not attempt to shift the transmission until after the extension housing is properly installed.

1. Assemble in the order indicated in the table..

32—45

13.8—25.4

5

4

3

16

17

14

13

6

1

15

R

R

R

SST GR

EA

SE

GR

EA

SE

17—23

2230—39

24—35

17—24

SEALANTSEALANT7

A

89

1012

11

5.9—10.7 N·m

32—45

MOLYBDENUM SULFIDE

GR

EA

SE

GR

EA

SE

*

24

27—48

27—48

R

R

AR

21

35—44

GR

EA

SE

GR

EA

SE

*

28

25

27

GR

EA

SE

GR

EA

SE

*

23 2019

18

2

7.9—10.7 N·m

26

{3.6—4.4, 26—32}

{3.3—4.5, 24—33}

{2.8—4.8, 20—35}

{1.8—2.4, 13—17}

{2.5—3.5, 18—25}

{1.4—2.5, 10.2—18.7} {3.3—4.5,

24—33}

{1.8—2.3, 13—16}

{3.1—3.9, 23—28}

{61—109 kgf·cm, 53.0—94.6 in·lbf}


{81—109 kgf·cm, 70.3—94.6 in·lbf}

{2.8—4.8, 20—35}

CHU0511M163

1 Oil seal(See 05–11–31 Oil Seal Assembly Note.)

2 Baffle plate3 Breather4 Lever support5 Oil funnel6 Stopper block7 Oil passage8 Shift rod9 Shift lever

10 Torsion spring(See 05–11–31 Torsion Spring Assembly Note.)

11 Shift rod and shift lever component

12 Retaining ring13 Extension housing component14 Control rod end15 Tubular pin16 Gasket17 Control case18 Push pin component19 Pressure spring20 Plug21 Back-up light switch22 Neutral switch23 Drain plug, gasket24 Filler plug, gasket

MANUAL TRANSMISSION

05–11–31

05–11

Oil Seal Assembly Note1. Install a new oil seal in the extension housing

using the SSTs and a hammer.

Torsion Spring Assembly Note1. Install the torsion spring to the shift lever as

shown in the figure.End Of Sie

25 Clutch release collar26 Pivot pin

27 Dust cover28 Clutch release fork

49 B025 001 49 G030 797

BHJ0511M167

BHJ0511M166

TECHNICAL DATA

05–50–1

05–50

05–50 TECHNICAL DATATECHNICAL DATA . . . . . . . . . . . . . . . . . 05–50–1

End of Toc

TECHNICAL DATACHU055001029M01

End Of Sie

Item SpecificationManual transmission type Y16M-D

Transmission oilType API Service GL-4 or GL-5Viscosity All-season SAE 75W-90Capacity (L {US qt, lmp qt}) 1.75 {1.85, 1.54}

Drive gear thrust clearance (mm {in})

1st 0.15—0.40 {0.006—0.015}2nd 0.10—0.45 {0.004—0.017}3rd 0.10—0.35 {0.004—0.013}4th 0.10—0.35 {0.004—0.013}6th 0.10—0.40 {0.004—0.015}Reverse 0.10—0.45 {0.004—0.017}

Drive gear radial clearance (mm {in})

1st 0.015—0.066 {0.0006—0.0025}2nd 0.015—0.066 {0.0006—0.0025}3rd 0.015—0.068 {0.0006—0.0026}4th 0.065—0.115 {0.0026—0.0045}5th (drive gear) 0.029—0.072 {0.0012—0.0028}6th 0.015—0.068 {0.0006—0.0026}Reverse 0.015—0.066 {0.0006—0.0025}

Reverse idler gear radial clearance (mm {in}) 0.040—0.082 {0.0016—0.0032}

Clearance between synchronizer ring and flank surface of gear

(mm {in})1st, 2nd, 3rd

Inner ring 0.98—1.62 {0.04—0.06}Middle ring 0.68—1.92 {0.03—0.07}Synchronizer ring 0.88—1.72 {0.04—0.06}

4th, 5th 0.80—1.60 {0.04—0.06}6th, Reverse 0.88—1.52 {0.04—0.05}

Mainshaft maximum runout (mm {in}) 0.03 {0.0012}Countershaft maximum runout (mm {in}) 0.03 {0.0012}Clearance between clutch hub sleeve and shift fork (mm {in}) 0.15—0.35 {0.006—0.013}Clearance between 4th gear inner race and thrust washer (mm {in}) 0—0.1 {0—0.0039}Clearance between counter drive gear and snap ring (mm {in}) 0—0.1 {0—0.0039}Clearance between roller bearing (countershaft) and snap ring (mm {in}) 0—0.1 {0—0.0039}Clearance between bearing (main drive gear) and snap ring (mm {in}) 0—0.1 {0—0.0039}Clearance between clutch hub component (5th/reverse) and snap ring (mm {in}) 0—0.1 {0—0.0039}

Clearance between 6th gear and snap ring (mm {in}) 0—0.11 {0—0.0043}Clearance between clutch hub component (6th) and snap ring (mm {in}) 0—0.1 {0—0.0039}

SERVICE TOOLS

05–60–1

05–60

05–60 SERVICE TOOLSSERVICE TOOLS . . . . . . . . . . . . . . . . . . 05–60–1

End of Toc

SERVICE TOOLSCHU056001029M01

End Of Sie

49 N017 2A1

Clutch hub puller set

49 G030 370

Removing plate

49 N017 101

Plate

49 B032 317

Bearing and oil seal remover

49 H027 002

Bearing remover

49 N017 102

Plate

49 F401 331

Body

49 M005 796

Body

49 N017 104

Joint pipe

49 H025 004

Bearing installer set

49 0500 330

Bearing installer set

49 B019 007

Preload adapter

49 N017 103

Gear installer

49 N017 204

Setting plate

49 N017 207

Shaft stopper

49 G030 797

Handle

49 N017 209

Oil seal installer

49 N017 2A0

Clutch hub installer set

49 N017 208

Guide pin

49 B025 001

Body

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Documents

Mazda RX8 transmission manual